Operating Instructions - Orbi-Tech
Contents
1. Flachkopfschraube 2x K03072 Washer 7 Compression spring Unterlegscheibe Druckfeder 2x K03070 2x K03071 Druckhebel K03067 Compression lever Page 14 20 Issue 12 2009 Rev 02 MUNSCH Kunststoff Schwei technik GmbH MUNSCH y Kunststoff Schwei technik Handle Handgriff K02941 Rohrheizpatrone Heating cartridge 230V K02603 Kompressionsd se K02922 Compression nozzle Vorw rmd se K02696 Preheat nozzle Sicherungsring K03035 Circlip D se K04509 Nozzle Schaltgeh use Unterteil mit Regler Typ K Control box bottom part with controller type K Sechskantmutter Innen 6kt Schraube Hex nut 2x K03350 Allen screw 2 3x K03410 Zylinderschraube Fillister head screw Anschlussplatine Typ K Connection PCB type K 2x K03351 K03990 Zahnscheibe Toothed disk 2 3x K04798 Zylinderschraube Fillister head screw Regler Controller Typ K m K03989 3x K03352 Eigenluftgebl se On board blower Lufterhitzer Air preheater UE E EN ERREA MLE 23 230V K04552 Handle Electronic unit Ceramic heating element Griffschale K04198 Elektronikeinheit K04232 Heizung Keramik K04234 Coupling Air preheater casing Verschraubung K03037 Lufterhitzer Geh use K04554 Heating system complete Heizung komplett K04318 Ausblasrohr K04237 Screw connector Hot air tube Hot air tube Einschraubt lle2. MA U N S C H Kunststoff Schwei technik Operating Instructions Type MEK 25 MAK 25 Serial No Article No A These operating instructions contain important information to be observed for hand extruder operation and maintenance It is therefore imperative that they be read and their contents fully understood by the operators before the hand extruder is placed in service MUNSCH Kunststoff SchweiBtechnik GmbH Issue 12 2009 Rev 02 Page 1 20 Hand Extruder MEK 25 MAK 25 Scope of delivery Please check that the delivery is complete The delivery comprises 1hand extruder 1 Container engineering design fillet weld a 7mm 40mm long 1 handle 1 Landfill construction design sheeting film weld 25mm 40mm long 1 welding shoe machined 1 1 extruder stand 1 hot air hood Contents 1 GENERAL ai A eoianetieee cede 4 2 SAFETY 2222 O ess savesceudedcedgadoancswedcadceustacewdeetevcceestacscanccsucveskeecstecees 4 2 1 IDENTIFICATION OF INFORMATION IN THE OPERATING INSTRUCTIONS cccscecececcecscececcecscecececcecscsceceseeescecuceseeescecs 5 22 PERSONNEL QUALIFICATION AND TRAINING cccccscccscsssccsccscsscccsccescsssccsscescsscccsscesessccesscescesecesssescssscesssescesccesseesess 5 2 RISKS RESULTING FROM NON OBSERVANCE OF THE SAFETY INSTRUCTIONS ccccscesceccecceccscescecceccscescescescecescescesens 5 24 eaaa A AEAT DA E E E A E E E a eee lets e ed E o N 5 2 5 SAFETY INSTRUCTIONS FOR OPERATOR
3. atmospheres Make sure that the hand extruder is firmly positioned during the extrusion welding job The connecting cable welding rod and hose for external air supply if applicable must be freely movable and must not obstruct the operator or third parties in their work A Hold and touch the hand extruder only on the handles provided for this purpose Do not touch bare metal parts including hot air hood either with or without gloves These parts reach temperatures of up to 350 Attachments may be damaged or impaired in their function if subjected to the full weight of the hand extruder Bare metal parts must not come into contact with other items during the work or work breaks e g cooling Hain A Contact of combustible components with hot bare metal parts poses a risk of fire Su 0001 Do not use synthetic gloves Page 6 20 Issue 12 2009 Rev 02 MUNSCH Kunststoff Schwei technik GmbH MUNSCH Kunststoff Schwei technik e Do not direct the hot air jet of the hand extruder towards living beings or temperature sensitive items Safety distance 2 m radius 360 m Ky DO2 0002 ad e Use suitable personal protection equipment for overhead work e g hard hat safety goggles gloves protective clothes to guard against falling items e During work breaks and after completion of the welding job place the hand extruder on the rests supplied for this purpose
4. 4 A gt f f 1 A y VA A lt gt f Pa DO2 0001 e Always transport or store the hand extruder in such a way as to preclude any mechanical loads on the attachments If parts have been removed for transport purposes mount and fasten them carefully before restarting the hand extruder Transport of the hand extruder in MUNSCH s original shipping case is recommended 3 2 Storage e Store the hand extruder in a dry and frost free place e Protect the hand extruder from unauthorized access e Special preservation is not required 3 3 Return to Munsch Should it become necessary to return the hand extruder to MUNSCH Kunststoff SchweiBtechnik GmbH always use the original shipping case 4 Product Description 4 1 Application range The application range of the hand extruder is defined by the data on the type tag and the service limits indicated in these operating instructions Operation of the hand extruder outside the service limits stated in these operating instructions is subject to the Manufacturer s prior approval 4 2 General Type MEK is a hand extruder with external air supply Type MAK is a hand extruder with integrated air supply Autoair Powerbox WX 2PBMU Powerbox WX 2PBMU is required for the operation of the hand extruder It consists of a power pack a frequency inverter and an EMC filter The drive speed and hence the melt throughput are
5. CAUTION The hot air hood must be remounted A Make sure that the hand extruder is firmly positioned Deposit the hand extruder in a dry location After completion of the welding job cool the hand extruder to safe to touch temperature using the air supply system A Do not operate dismantle or carry out any modifications on the hand extruder if the connecting cable or the mains connector is defective safety devices are damaged foreign matter or liquid has penetrated into the hand extruder the unit does not work properly or there are unusual changes in its operating behaviour A Never allow the hand extruder to come into contact with water Hazard to persons and equipment short circuit risk 2 6 Safety instructions for maintenance inspection and mounting The Operator is responsible for ensuring that maintenance inspection and mounting activities are performed by authorized and qualified personnel who are thoroughly familiar with the operating instructions e As arule the hand extruder must be shut off and the connector unplugged before proceeding to any work on the unit The shutoff procedure for the hand extruder described in the operating instructions must be strictly observed e Electrical hazards must be ruled out for details see VDE guidelines and the standards of your local electric utility for instance A VDE 0701 IEC 335 prescribes the measurement of the protective conductor r
6. GmbH yMunscn Kunststoff SchweiBtechnik Operating Instructions MUNSCH controller MA EK 25 40 65 36 48 58 from Software 1v56 onwards Bedienungsanleitung MUNSCH Regler MA K 25 40 65 36 48 58 ab Software 1v56 Select Material POM AMAT ATR POM HAT HIK De ey 251331181 heating systems OFF Heizungssysteme Aus melt temperature Masse JANBEIZUN 2 III FOH HAT ATR Pa a PD AIR Pou un HIR zu vA mari 2 A SE le Fe 2251031081 em E mese SA A e pus o r 80 me pe Og s ann air temperature Luft Temperatur u ui FOH HAT THIR Z Hd AHAT o oe a MAT ATA FO MATA AIR h gt bola OTRO ne wae Sch Jazzi JEEN eae ET aso N elle on Seeds 80 2240311080 REES Display design Display Beschreibung ENTER push button and Best tigungstaste und Taste zur power melt Masse air Luft Ipush button for Select Speed Anderung der Motordrehzahl PL I zu AE e i gt setpoint Soll Temp RETURN push button and Zur cktaste und Ausschalten Bu gt gt i loush button for switch off heating systems der Heizsysteme r 1 Zi ii L gt lactual value Ist Temp a DOWN push butten Menue and Runter Taste zur nderung E a SELECT MELT for change the melt temperature der Massetemperatur I I I o I UP push butten Menue and Hoch Taste zur Anderung J a Off Time r error message Select AIR for change the air temperature der
7. OPERATING PERSONNEL sccsceccsceccececcececcsceccscecescecscscscscesescusescusescusescs 5 2 6 SAFETY INSTRUCTIONS FOR MAINTENANCE INSPECTION AND MOUNTING ccsccececceccecceccececcescsccscescescescecescescuses 7 2 7 UNAUTHORIZED MODIFICATIONS AND SPARE PARTS ccscececcscecececcecscscececcecscececscecscscusecscscecesescecececesesescecesesesescecs 7 3 TRANSPORT AND STORAGE lt a ce 8 3 1 IDRANSPORT zu 0 ee a il ed ooo ela eno ADE doo 8 3 2 A E A RO 8 3 3 RETURN TO MUNI e ee ron A e O 8 4 PRODUCT DESCRIPTION 2 2 222 2 we rE EANA EENS 8 4 1 APPLICATION RANGE i goes aca aah eg ee aaa it gO te cana i ig Gt ote adele ant Mal i ag Sa iat 8 4 2 GENERA 0 eas A E ANS aa IN NO 8 5 STARTUP AND SHUTOERF 2232 22 os 9 5 1 EN ne ee A NE OTe RIE SON ORE CERN a O A 9 32 PREPARSTION ee ee rer leere Ede ee 9 5 3 STAR PING THE HAND EXTR DER 2 a aa sion diese r eigener AE ee 10 5 4 WELDING WITH THE HAND EXTRUDER ii 11 5 4 1 introduce tho weldino 1700 en na ae 11 5 4 2 Replacement and aso Gt wena Tod a na anal 11 5 4 3 W Claim sire CU OM Tale nuroa ora 11 5 4 4 NILE GRUP MONGOL work aan 11 5 4 5 SS UO ego sts TN 12 5 4 6 BRATS ORG SLOT AG dai 12 5 5 SET TEMPERATURES ON TEMPERATURE CONTROLLER ccceccsceccsceccececcececcsceccececescscecscscscesescecescesescscescncescscusesces 12 5 51 BSF CC MEO TA N ee ee ee ee ae 12 6 MAINTENANCERAINSPEETION a en a se a e ad 14 6 1 MAINTENANCE INSPECTION OF MEK MAK HAND EXTRUDER ccce
8. fire 2 Safety These operating instructions provide basic information to be observed for operation and maintenance For this reason it is imperative that they be read by the specialist personnel Operator prior to placing the hand extruder in service and that they always be available at the place of use Safe operation of the hand extruder presupposes that the instructions under section 1 General of these operating instructions are complied with In no case must the limit values indicated be violated Intact and unaltered hand extruders conform to the applicable codes and standards and meet all regulatory limit values regarding EMC electromagnetic discharges and interference immunity For the country specific limit values to be observed the Operator should consult the local electric utility Nevertheless the hand extruders emit electromagnetic fields within the acceptable limits Electromagnetic fields may interfere with the operation of vital electronic devices e g cardiac pacemakers Persons wearing a cardiac pacemaker should therefore consult their physician before using the machine In addition to the operating instructions and the national and local accident prevention regulations applicable at the place of use the acknowledged technical rules for safe and proper working practices must be observed Apart from the general safety instructions under section Safety also the special safety instructions given
9. joint width at as low a hot air temperature as possible For larger weld seam widths a wider preheat nozzle is available as an accessory 5 3 Starting the hand extruder A Observe section Safety e CAUTION Never operate the hand extruder without air supply Otherwise the unit may suffer severe damage e CAUTION Before plugging in the mains connector check that the drive unit is not set to continuous operation CAUTION The hot air hood must be in place CAUTION Start external air supply for MEK hand extruder CAUTION Connect the cable between the Powerbox and the hand extruder CAUTION Plug in mains connector CAUTION In the case of the MAK hand extruder with integrated air supply the blower must start automatically CAUTION Once air exits the preheat nozzle 4 the heating systems for the air melt temperatures may be activated Temp rature mati re Temperature d air Massetemperatur melt Lufttemperatur air Valeur de consigne Sollwert setpoint Istwert actual value 1 Valeur reelle enter return select entrer retour selection For the operation of the temperature controller see section 5 5 Set temperatures For temperature settings see page 12 The hand extruder will reach its operating temperature after about 10 to 15 minutes Set the drive speed to maximum and select the speed on the Powerbox Page 10 20 Issue 12 2009 Rev 02 MUNSCH Kunsts
10. remedial work The procedure for claims under this warranty shall be as follows The Purchaser may assert claims under this warranty either with his dealer or with a company authorized by the Manufacturer to provide services for the purchased article The Purchaser shall give written notice of defects to the respective company promptly after such defects have been identified or shall have such defects registered by the respective company 3 2 Defects shall be promptly remedied in accordance with the technical requirements by either replacement or repair of the defective parts the cost of the remedial work being for the account of the Manufacturer Replaced parts shall become the property of the Manufacturer If as a result of the remedial work additional maintenance measures are prescribed by the Manufacturer the resulting costs including the costs of materials and lubricants shall be for the Manufacturer s account 3 3 For replacement parts installed within the scope of the remedial work a warranty will be provided under the purchase contract the warranty period for such parts ending on expiry of the warranty period of the object purchased 3 4 For the warranty to become effective this warranty certificate must be produced for each repair 4 Ifthe defect cannot be remedied or if the Purchaser cannot be reasonably expected to accept any further attempts at making good the defect the Purchaser may demand annulment cancell
11. set on the Powerbox The Powerbox has three LEDs red undervoltage defective yellow temporary drive overload green normal operation Page 8 20 Issue 12 2009 Rev 02 MUNSCH Kunststoff Schwei technik GmbH MUNSCH Kunststoff Schwei technik For both types of hand extruder the following parameters can be freely selected welding rate hot air temperature melt temperature and throughput the melt throughput can be controlled downward from the maximum value firstly by using 3 mm instead of 4 mm welding rod and secondly by reducing the speed using the rotary button on the Powerbox or the fine tuning button of the drive CAUTION Too low a speed will cause a risk of drive overheating Driven by a powerful electric motor 1 the welding rod 2 is fed into the extruder 3 and granulated by the extruder screw in the process The screw forces the granulate into the extruder nozzle melting it into a homogeneous completely plastified mass As the molten material exits the extruder nozzle it is moulded by a welding shoe 4 to the geometry of the weld seam to be deposited Preheating of the base material to be joined is accomplished by a preheating nozzle 5 which is supplied from an integrated hot air unit 6 Air is supplied either from an external compressor or an on board blower Melt and preheat temperatures are controlled separately The setpoint and momentary values are displayed con
12. K00549 Ausblasrohr K04320 MEK 25 MAK 25 Issue 12 2009 Rev 02 Page 15 20 Hand Extruder MEK 25 MAK 25 7 Malfunctions Causes and Remedies 7 1 Trouble shooting The following table lists potential operating upsets of Should malfunctions occur which are not covered the hand extruder possible causes and their here or which cannot be traced back to the cause remedies fault diagnosis chart stated please contact MUNSCH Kunststoff Schwei technik GmbH Drive motor does not start 5 8 9 10 11 12 14 15 16 17 18 19 21 23 25 Drive motor switches off 5 8 9 10 11 12 14 15 16 17 18 19 21 23 25 No welding rod feed 1 16 17 20 No extrudate conveyed out of welding shoe 1 16 Extrudate output decreases during operation 1 14 16 No air supply 6 7 13 Integrated air supply without function 5 22 No hot air 2 3 4 5 6 18 22 Hot air temperature below setpoint temperature 2 3 4 8 10 18 22 14 Melt temperature below setpoint temperature 2 3 9 11 14 Extruder does not heat up 2 3 12 22 Temperature above preset range 2 3 18 19 Controller fault signal E 2 Controller fault signal OEAIR 2 13 22 Controller signal OFF 9 10 11 12 Control fluctuates 3 13 19 12 7 2 Fault diagnosis Ko Possible causes Remedies 1 Smaller or too small a welding rod diameter Use larger welding rod diameter if necessary __ 2 Temperature sensor defectiv
13. Lufttemperatur Ein Aus Zeitschaltung Fehlermeldung N A L l 7 Select Material 4 HATH MENU p 4 CONFIGURATION P 4 SETTINGS r EE Z o o Start Hork Kerna gt e Fr Offe FoC far conf igurat ion Edit Material Lcd C 60 Display Contrast star Service JA 5s5 4 CONFIGURATION PassWord Pre A 8980 Ze Lect Fo Er Edit JEDIT USER 1 3 JEDIT USER 273P JEDIT USER 373 gt ETAIT 260 eTMHat 230 home User i TAir iz 50 Thea 2s Sox TAIT wi ar Bl yla ase a a Bei den User Men s 1 2 3 und 4 sind alle Positionen frei programmierbar In User Menues 1 2 3 and 4 are all positions complete free programmable Select for Edir JEDIT 4EDIT PP PE PVDF Yj o ETAIT as o rMat asort Bei den Hauptmen s PP PE PVDF und PVC U k nnen nur die Abgleichwerte ver ndert werden In the main menues PP PE PVDF and PVC U only the setoff s changeable ETAIT a fc Abgleich der Luft und Masse Temperaturen Calibration from air and melt temperature Messung der Temperatur mit externem Thermometer ist measuring of temperature with external Temperature probe is zu kalt den Abgleich in den PLUS Bereich verschieben too cold shift comparsion into PLUS area zu warm den Abgleich in den MINUS Bereich verschieben too hot shift comparision into MINUS area Notizen Abgleiche user 1 4 notes configuration user 1 4 By Zl MEK 25 MAK 25 Issue 12 2009 Rev 02 Page 13 20 Hand Extruder MEK 25 MAK 25 6 Maintenance Inspe
14. andle Loosen handle 55 and move it to the ideal working position by pushing it back and forth The handles of these extruder models can also be swivelled upward and downward e Only for MEK hand extruder with external air supply Connect the hand extruder to the external air source using the hose coupling LW 13 NM 7 2 provided for this purpose quick connect disconnect set air rate to 300 l min at 0 4 bar A suitable controller with flow metering function is recommended for setting the air rate CAUTION The supply air must be clean dry and free from oil and water Never connect an external air source to a MAK hand extruder MEK 25 MAK 25 Issue 12 2009 Rev 02 Page 9 20 Hand Extruder MEK 25 MAK 25 e Mount welding shoe Select the welding shoe required for the specific weld geometry or machine a welding shoe blank to the required geometry Observe DVS 2207 Guideline Part 4 for machining welding shoe blanks Mount welding shoe to the hand extruder in the position required for welding Observe welding direction Tighten set screw 25 e The welding shoe including preheat nozzle can be rotated through 360 by releasing the set screw 25 After rotating the welding shoe o tighten set screw 25 to fix the welding shoe in place for the welding operation Care must be taken to ensure that the preheat nozzle provides intensive and uniform preheating melting of the base material over the entire
15. ation of the contract or a price reduction reduction of compensation in lieu of remedial work In such a case the Purchaser shall not be entitled to any replacement 5 Manufacturer s warranty obligations shall not be affected by a change in ownership of the purchased article 3 k MUNSCH Kunststoff SchweiBtechnik GmbH Im Staudchen e D 56235 Ransbach Baumbach P O Box 142 e D 56221 Ransbach Baumbach Germany Phone 49 0 26 23 8 98 80 Telefax 49 0 26 23 8 98 85 Internet http www munsch de Email munsch munsch de 6 Any damage incurred through the following acts or omissions of Purchaser shall be expressly excluded from this warranty 6 1 Purchaser s failure to report a defect pursuant to subsection 3 1 or to promptly provide an opportunity to remedy the defect following Manufacturer s request or 6 2 improper handling or overload operation of the purchased article or 6 3 prior repair maintenance and servicing of the purchased article by a company not authorized by the Manufacturer if the Purchaser can be reasonable expected to have known that such company was not authorized or 6 4 the installation of parts into the purchased article without having obtained Manufacturer s prior approval for such parts or the modification of the purchased article in a way not approved by the Manufacturer or 6 5 Purchasers failure to observe the instructions given in the user s manual accompanying the purchased article
16. ccsceccsceccececcececescecscscescscescscusescesescusescecesctcess 14 6 2 DISMANTEING2 2 o ee ee een elegant 14 6 2 1 Overview of Spare Paits attachmentsn sea SEHE 14 7 MALFUNCTIONS CAUSES AND REMEDIES o sosssuconsesonnesonnssonnssunnnesonnesonnssonnsnunnnesonnesonnsnonnsnnnnnesonnesennssennsee 16 7 1 ROU BEES HOO TUNG da ne el ne e e Gada 16 7 2 Ee OBIE O e EEA ee ea ee ES EER ETENE A EEE na e LS 16 8 TECHNICAL DATA z 2er alan cacti Reena Resse ees aie 18 Page 2 20 Issue 12 2009 Rev 02 MUNSCH Kunststoff Schwei technik GmbH MUNSCH Kunststoff Schwei technik EG Konformit tserkl rung des Herstellers nach der EG Maschinenrichtlinie 2006 42 EG Anhang ll Nr 1 A EC Declaration of Conformity by the Manufacturer as defined by machinery directive 2006 42 EC Annex Il No 1 A MUNSCH Kunststoff Schwei technik GmbH Im Staudchen D 56235 Ransbach Baumbach Germany Mr Johann Dausenau Kunststoffschwei technik GmbH is authorised to compile the technical documentation We hereby declare that the hand extruders Machine type Hand extruder Hand extruder Type designation MEK 25 MAK 25 are in accordance with all relevant provisions of the EC Machinery Directive The following harmonised standards or parts of these standards were applied x DINEN ISO 12100 1 2004 XX DIN EN 13732 1 2008 x DINEN ISO 12100 2 2004 In addition the hand extruders are in accordance with the following EC directive
17. ction IN Pull mains connector before carrying out any maintenance and repair work on the hand extruder Maintenance and repair work on electrical tools may only be carried out by qualified electricians A The hand extruder together with the hot air hood must have cooled down to safe to touch temperature Observe the instructions under section Safety Maintenance and repair work may only be carried out by qualified personnel or by our service staff To ensure the proper function of the hand extruder over its entire service life for its intended service we recommend to have all maintenance inspection and mounting work carried out by authorized and qualified personnel who are familiar with the operating instructions to always shut off the unit before carrying out any work on it to remount and reactivate all safety and protective devices immediately after completion of the maintenance repair work During maintenance and repair work make sure that the hand extruder and its individual components are firmly positioned In addition to the operating instructions and the national and local accident prevention regulations applicable at the place of use the acknowledged technical rules for safe and proper working practices must be observed Any working practices posing a safety risk are prohibited A Activities other than those described in this section may only be performed at the Manufacturer s workshops 6 1 Mai
18. currently Temp rature d air Lufttemperatur air Temp rature mati re Massetemperatur melt Valeur de consigne Sollwert setpoint Istwert actual value 1 Valeur reelle enter return select entrer retour selection The melt temperature must have reached the preset start interlock temperature for the startup timer to be activated After the startup timer has timed out the start interlock will be released and the extruder can be started The temperature controlled start interlock prevents the drive from starting if there is still unmolten material in the extruder thus precluding damage to the unit The output rate is variable so that the preheat temperature can be matched to the weld thickness 5 Startup and Shutoff 5 1 General In addition to the operating instructions and the national and local accident prevention regulations applicable at the place of use the acknowledged technical rules for safe and proper working practices must be observed Any working practices posing a safety risk are prohibited Before starting shutting off the hand extruder make sure to carefully read the instructions under section Safety Only trained and qualified personnel may be assigned to the operation of the hand extruder 5 2 Preparation e Place hand extruder and Powerbox on a firm support and secure them against toppling over e Mount hot air hood e Position h
19. d thread Electronic control defective Controller programming error Welding rod feed Remove welding rod A Observe instructions in section Maintenance 17 Drive unit defective 1 1 Observe instructions for operation P f Check voltage supply Allow hand extruder to heat up 1 Consult MUNSCH Kunststoff Schwei technik GmbH 2 Only for MAK 3 Only for MEK MEK 25 MAK 25 Issue 12 2009 Rev 02 Page 17 20 Hand Extruder MEK 25 MAK 25 8 Technical Data Type designation MEK CMA Welding materials PP PE PVDF PP PE PVDF Welding rate approx 25 Y 3 mm 1 4 kg h PP PE 25 Y 3 mm 1 4 kg h PP PE 25 4 mm 2 5 kg h PP PE 25 Y 4 mm 2 5 kg h PP PE Welding rod Welding rod 3 and 4 mm Welding rod 3 and 4 mm Application range 25 Wall thicknesses 4 15 mm and 25 Wall thicknesses 4 15 mm and film sheeting welds film sheeting welds Weight 25 5 kg 25 6 kg Drive 230 V AC with speed control external 230 V AC with speed control external Powerbox Powerbox 300 l min at 0 4 bare Control of melt Temperature controller with concurrent Temperature controller with concurrent temperature momentary value and setpoint display momentary value and setpoint display Control of air Temperature controller with concurrent Temperature controller with concurrent temperature momentary value and setpoint display momentary value and setpoint display Cold start protection Start temperatur
20. e Do o oo 3 Temperature controller defective S o 4 Arratetoohigh______________ Reduceairratetospecifiedleve 5_ Cable connections defective Check cable connections er External air supply not connected Connect external air supply External air supply without function Switch on external air supply Check the external air supply system for malfunctions using the separate manual or have it checked Hot air temperature below start interlock Allow hand extruder to heat up temperature Air rate too high gt reduce air rate 1 Consult MUNSCH Kunststoff Schwei technik GmbH a Only for MAK 3 Only for MEK Page 16 20 Issue 12 2009 Rev 02 MUNSCH Kunststoff Schwei technik GmbH MUNSCH Kunststoff Schwei technik Melt temperature below start interlock Allow hand extruder to heat up temperature Preheat time for hot air too short Allow hand extruder to heat up Preheat time for melt too short Allow hand extruder to heat up Heating cartridge defective n Air supply not constant External air supply Check air supply unit Integrated air supply 1 Wrong rated voltage Rated voltage gt permissible voltage Check mains voltage Rated voltage lt permissible voltage Check mains voltage 1 Extension cable heats up Unroll cable reel Check cable cross section see also section Safety Extruder nozzle plugged with foreign matter Clean extruder A Extruder nozzle left han
21. e g operation maintenance and care or 6 6 Purchaser having removed the serial number or made it illegible 7 Natural wear and tear shall be expressly excluded from this warranty 8 Accidents force majeure or other circumstances beyond the control of the Manufacturer in particular damage caused by lightning overvoltage water fire etc shall be excluded from this warranty 9 All rights under this warranty shall become null and void on expiry of the warranty term pursuant to Section 1 For claims asserted within the warranty term but no settled by its expiry the warranty shall remain effective until the respective defect has been remedied The period of limitation shall be suspended for such claim Page 20 20 Issue 12 2009 Rev 02 MUNSCH Kunststoff SchweiBtechnik GmbH
22. e interlock and startup Start temperature interlock and startup timer for melt and preheat air timer for melt and preheat air Page 18 20 Issue 12 2009 Rev 02 MUNSCH Kunststoff Schwei technik GmbH MUNSCH Kunststoff Schwei technik Warranty Certificate Name and address of Purchaser Type of unit Hand extruder Type designation Serial no P O date Your warranty MUNSCH Kunststoff Schwei technik GmbH hereby warrants the unit to be free from defects in materials and workmanship from the date of its first acquisition Should deficiencies resulting from defects in materials or workmanship be identified during the warranty period the dealers will in accordance with the following terms and conditions repair the unit or at their discretion replace either the complete unit or the defective components without charging labour or material costs Dealer s stamp and signature MEK 25 MAK 25 Issue 12 2009 Rev 02 Page 19 20 Hand Extruder MEK 25 MAK 25 Warranty 1 The Manufacturer warrants freedom from defects in materials and workmanship and state of the art performance of the purchased article for a period of six 6 months from the date of delivery 2 The Purchaser shall check the article delivered for completeness and freedom from defects immediately after receipt 3 The Purchaser shall be entitled to the making good of defects and any resulting damage to other parts of the purchased article
23. erved by all persons working with on the hand extruder Such work includes for instance e operation e maintenance inspection and repair e transport The hand extruder may only be mounted operated and maintained by trained personnel In addition to the operating instructions and the national and local accident prevention regulations applicable at the place of use the acknowledged technical rules for safe and proper working practices must be observed These operating instructions provide basic information to be observed for operation and maintenance For this reason it is imperative that they be read by the specialist personnel Operator prior to placing the hand extruder in service and that they always be available at the place of use Apart from the general safety instructions under section Safety also the special safety instructions given under the respective sub sections must be adhered to A Non observance of the safety instructions may cause hazards to persons and the environment or damage to the hand extruder Moreover failure to observe the safety instructions may lead to the forfeiture of any damages Non observance of the safety instructions may in particular involve the following risks e failure of important hand extruder functions e hazards to persons due to electrical and mechanical impacts including risk of burns e hazards to the environment due to vapour phase hazardous substances e risk of
24. esistance insulation resistance and leakage current after each repair or modification to electrical equipment Furthermore a visual inspection of the unit and its connecting cable as well as voltage and current measurements and a function test must be carried out e Ensure the safe and environmentally compatible disposal of media auxiliary materials and replaced parts e Remount and reactivate all safety and protective devices immediately on completion of the maintenance inspection or repair work 2 7 Unauthorized modifications and spare parts Modifications or changes to the unit are only allowed after consultation with the Manufacturer In the interest of safety only original spare parts and accessories authorized by the Manufacturer should be used The use of components other than the original spare parts may invalidate the Manufacturer s liability for any resulting damage MEK 25 MAK 25 Issue 12 2009 Rev 02 Page 7 20 Hand Extruder MEK 25 MAK 25 3 Transport and Storage 3 1 Transport A Before transport and storage make sure that the hand extruder has cooled down to safe to touch temperature A Hold and touch the hand extruder only on the handles provided for this purpose Do not touch bare metal parts including the hot air hood whether with or without gloves before having made sure that they are safe to touch These parts reach temperatures of up to 350 during operation e y y
25. he connector of the hand extruder e When using an extension cable make sure to observe the minimum conductor cross section Use extension cables with protective conductor only m mm 20 50 1 for 230 V AC 6 0 MEK 25 MAK 25 Issue 12 2009 Rev 02 Page 5 20 Hand Extruder MEK 25 MAK 25 Extension cables must be certified for the specific service conditions e g outdoor service and identified accordingly Always handle the connecting cable with care Do not kink the connecting cable Do not place any objects on the cable Do not jam or squeeze the connecting cable nor pull it over sharp edges Protect the connecting cable from moisture IN Do not touch the mains connector or connecting cable with wet hands Hold the cable always at the connector when plugging or unplugging it CAUTION Power generator sets used for power supply must be designed for the following rated output gt 4 x rated output of hand extruder IN Never allow the hand extruder to come into contact with water Hazard to persons and equipment short circuit risk CAUTION Never operate the hand extruder without air supply risk of hand extruder damage When using an external air source make sure that the air supply line is adequately dimensioned CAUTION The supply air must be clean dry and free from oil and water A The hand extruder must not be used in explosion hazard areas or flammable
26. nstructions is fully understood by the operating personnel 2 3 Risks resulting from non observance of the safety instructions Non observance of the safety instructions may cause hazards to persons and the environment or damage to the hand extruder Moreover failure to observe the safety instructions may lead to the forfeiture of any damages Non observance of the safety instructions may in particular involve the following risks e failure of important hand extruder functions e hazards to persons due to electrical and mechanical impacts including risk of burns e hazards to the environment due to vapour phase hazardous substances e risk of fire 2 4 Safe working practices The safety instructions given in these operating instructions the applicable national accident prevention regulations and any existing in company work instructions operating and safety procedures issued by the Operator must be followed 2 5 Safety instructions for Operator operating personnel e Before placing the hand extruder in service check the mains voltage and frequency against the data indicated on the type tag The allowable tolerances are 5 for voltage and or 2 for frequency e According to VDE 0100 55 the hand extruder must be operated via a residual current operated circuit breaker or an isolating transformer e CAUTION During hand extruder operation under load a voltage of not less than 230 V must be available at t
27. ntenance inspection of MEK MAK hand extruder After approx 500 operating hours the hand extruder including drive unit must be thoroughly cleaned and inspected This work may only be carried out at the manufacturer s workshops Cables switches plug in connections must be inspected by qualified staff every three months requirement according to VBG4 the inspection results must be documented 6 2 Dismantling Prior to dismantling the hand extruder pull the mains connector The hand extruder must be at ambient temperature Damaged power cables and or connecting cables between the Powerbox and the hand extruder must be completely replaced Mended cables pose a hazard to life and limb Cable replacement is to be carried out by qualified electricians only The safety precautions described under sections Safety and Malfunctions Causes and Remedies must be strictly adhered to 6 2 1 Overview of spare parts attachments When ordering spare parts always indicate the serial number of the extruder Make sure to use original spare parts only For spare parts supply contact MUNSCH Kunststoff Schwei technik GmbH Extruder screw bearing K02669 Axial bearing replace K04361 Ball bearing replace K04362 Circlip replace if necessary K02965 Seal ring replace K02698 Spacer ring replace if necessary Compression lever assembly Baugruppe Druckhebel 18 25 Pan head screw
28. rer retour selection A Maintain the air supply of the hand extruder until the unit has completely cooled down e Pull mains connector 5 4 5 2 Hand extruder with external air supply type MEK e Press return button once to switch off the heating circuits e Pull mains connector A Maintain the air supply of the hand extruder until the unit has completely cooled down A Never use water or another coolant to accelerate the cooling process 5 4 6 Transport Storage Make sure to observe the instructions under section Transport Storage 5 5 Set temperatures on temperature controller The default settings for the melt and air temperatures of the MEK and MAK hand extruders are shown in the following temperature chart The values have been determined with the aid of reference materials Temperature chart for MEK MAK Material Melt temperature Air temperature PP 200 240 250 300 200 240 250 300 PVDF 240 260 280 350 C If other temperatures are needed the corresponding settings can be made on the temperature controller 5 5 1 Set temperatures Temp rature mati re Massetemperatur melt Temp rature d air Lufttemperatur air Valeur de consigne Sollwert setpoint Istwert actual value 1 Valeur reelle enter return select entrer retour selection Page 12 20 Issue 12 2009 Rev 02 MUNSCH Kunststoff SchweiBtechnik
29. s e The DVS guideline also recommends this procedure for hand extruders which have been out of service for prolonged periods while still being filled with welding rod o A Ensure safe and environmentally compatible disposal of any waste generated 5 4 3 Welding direction rate e The pressure of the discharging extrudate causes the welding shoe and hence the hand extruder to move in welding direction See DVS Guidelines for the welding rate D02 0026 5 4 4 Interruption of work A Observe section Safety Do not leave the hand extruder unattended Make sure to maintain the air supply e When interrupting the welding job switch off the drive unit and deposit the hand extruder as shown in the illustration below MEK 25 MAK 25 Issue 12 2009 Rev 02 Page 11 20 Hand Extruder MEK 25 MAK 25 5 4 5 Shutoff A Observe section Safety e After completion of the welding job switch off the drive unit and deposit the hand extruder as shown in the illustration see preceding section A Do not leave the hand extruder unattended 5 4 5 1 Hand extruder with integrated air supply type MAK e Press return button once to switch off the heating circuits Temp rature mati re Massetemperatur melt Temp rature d air Lufttemperatur air Valeur de consigne Sollwert setpoint Istwert actual value Valeur r elle enter return select ent
30. s standards codes and regulations EU EMC Directive 89 336 EC DIN EN 55014 1 2007 DIN EN 55014 2 2009 Xx EU Low Voltage Directive 73 23 EC EN 60204 1 VDE 0113 Part 1 2007 EN 61029 1 VDE 0740 Part 500 2003 VDE 0701 Part 1 2008 VDE 0702 Part 1 2003 O LI RX DA lt Xx Bl D lt This industrial tool complies with the aforesaid standards insofar as it is used at the contractually agreed conditions The operator is responsible for this Inthe event of any modifications to the machine unit or use not as intended this declaration becomes invalid unless the manufacturer s prior written approval has expressly been given Shon Mensch Ransbach Baumbach 29 12 2009 Dipl Ing Stefan Munsch Managing Director MEK 25 MAK 25 Issue 12 2009 Rev 02 Page 3 20 Hand Extruder MEK 25 MAK 25 1 General A These operating instructions must always be available at the place of use of the hand extruder The objective of these operating instructions is to support operators in familiarizing themselves with the hand extruder and in using its functions for the intended service These operating instructions provide important information for the safe workmanlike and economical operation of the hand extruder Their observance helps avoid danger minimize repair costs and downtimes enhance reliability and extend the service life of the hand extruder These operating instructions must be obs
31. toff Schwei technik GmbH MUNS Ch Kunststoff SchweiBtechnik A Hold and touch the hand extruder only on the handles provided for this purpose D02 0001 e The melt temperature must have reached the preset start interlock temperature for the startup timer to be activated After the startup timer has timed out the start interlock will be released and the extruder can be started In addition to the start temperature interlock the brushless drive is equipped with a torque control which prevents the extruder from starting as long as the operating temperature is not reached and or melting of the extrudate is incomplete 5 4 Welding with the hand extruder A Observe section Safety and the data sheet General Welding is to be carried out in accordance with the guidelines of the German Association for Welding Technology Deutscher Verband f r Schwei technik DVS The parts to be joined and the welding rod must be clean and dry 5 4 1 Introducing the welding rod e CAUTION The hand extruder is provided with a bore for introducing the welding rod Schwei draht Welding rod Cordon de soudure 3mm oder or ou 4mm 5 4 2 Replacement and aging of welding rod e lf the welding rod is to be replaced make sure that any remaining rod in the hand extruder is completely removed e For this purpose operate the preheated hand extruder with the new welding rod until clean new material discharge
32. under the respective sub sections must be adhered to Any working practices posing a safety risk are prohibited Page 4 20 Issue 12 2009 Rev 02 MUNSCH Kunststoff Schwei technik GmbH MUNSCH Kunststoff Schwei technik 2 1 Identification of information in the operating instructions In these operating instructions safety instructions whose non observance may cause hazards to persons are identified with Hazard symbol according to DIN 4844 W 9 for general hazards and with Hazard symbol according to DIN 4844 W 8 for electrical hazards Safety instructions whose non observance may cause damage to the hand extruder and its functions are marked with CAUTION Instructions directly indicated on the hand extruder must be strictly followed and kept in a fully legible state 2 2 Personnel qualification and training The operating maintenance and inspection personnel must possess appropriate qualification for the work to be performed Functional and technical responsibilities and supervision of the operating personnel must be clearly regulated by the Operator Where the personnel do not have the necessary skills and knowledge they must be trained and instructed e g a DVS basic welder training in extrusion welding A detailed instruction into hand extruder operation will be provided by the Manufacturer Supplier on request Furthermore the Operator has to make sure that the contents of the operating i
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